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TIMING BELTS, PULLEYS, CHAINS AND SPROCKETS
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Additional guidelines that may be useful in designing registration critical drive systems are as follows:
Select PowerGrip GT2 or trapezoidal timing belts.
Design with large pulleys with more teeth in mesh.
Keep belts tight, and control tension closely.
Design frame/shafting to be rigid under load.
Use high quality machined pulleys to minimize radial runout and lateral wobble.
SECTION 10 BELT TENSIONING
10.1 What Is Proper Installation Tension
One of the benets of small synchronous belt drives is lower belt pre-tensioning in comparison to
comparable V-belt drives, but proper installation tension is still important in achieving the best possible
drive performance. In general terms, belt pre-tensioning is needed for proper belt/pulley meshing to prevent
belt ratcheting under peak loading, to compensate for initial belt tension decay, and to prestress the drive
framework. The amount of installation tension that is actually needed is inuenced by the type of application
as well as the system design. Some general examples of this are as follows:
Motion Transfer Drives: Motion transfer drives, by denition, are required to carry extremely light torque
loads. In these applications, belt installation tension is needed only to cause the belt to conform to and mesh
properly with the pulleys. The amount of tension necessary for this is referred to as the minimum tension (T
st
).
Minimum tensions, on a per span basis, are included in Table 9, on page T-30. Some motion transfer drives
carry very little torque, but have a need for accurate registration requirements. These systems may require
additional static (or installation) tension in order to minimize registration error.
Normal Power Transmission Drives: Normal power transmission drives should be designed in
accordance with published torque ratings and a reasonable service factor (between 1.5 and 2.0). In these
applications, belt installation tension is needed to allow the belt to maintain a proper t with the pulleys while
under load, and to prevent belt ratcheting under peak loads. For these drives, proper installation tension can
be determined using two different approaches. If torque loads are known and well dened, and an accurate
tension value is desired, Equation (10-1) or Equation (10-2) should be used. If the torque loads are not as well
dened, and a quick value is desired for use as a starting point, values from Table 10 can be used. All static
tension values are on a per span basis.

0.812 DQ
T
st
= + mS
2
(lbf) (10-1)
d
(For drives with a Service Factor of 1.3 or greater)
1.05 DQ
T
st
= + mS
2
(lbf) (10-2)
d
(For drives with a Service Factor less than 1.3)
where: T
st
= Static tension per span (lbf)
DQ = Driver design torque (lbf in.)
d = Driver pitch diameter (in.)
S = Belt speed/1000 (ft./min.)
where Belt speed = (Driver pitch diameter x Driver rpm)/3.82
m = Mass factor from Table 9
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Registration Drives: Registration drives are required to register, or position accurately. Higher belt installation
tensions help in increasing belt tensile modulus as well as in increasing meshing interference, both of which
reduce backlash. Tension values for these applications should be determined experimentally to conrm that
desired performance characteristics have been achieved. As a beginning point, use values from Table 10
multiplied by 1.5 to 2.0.
Minimum T
st
(lbf)
Per Span
Belt
Width
Belt m Y
4 mm
6 mm
9 mm
12 mm
6 mm
9 mm
12 mm
15 mm
9 mm
15 mm
20 mm
25 mm
6 mm
9 mm
15 mm
9 mm
15 mm
25 mm
1/8"
3/16"
1/4"
1/4"
3/8"
1/2"
3/4"
1"

4 mm
6 mm
10 mm
6 mm
10 mm
16 mm
16 mm
25 mm
2 mm GT2
3 mm GT2
5 mm GT2
3 mm HTD
5 mm HTD
MXL
XL
L
T2.5
T5
T10
0.026
0.039
0.058
0.077
0.077
0.120
0.150
0.190
0.170
0.280
0.380
0.470
0.068
0.102
0.170
0.163
0.272
0.453
0.003
0.004
0.005
0.010
0.015
0.19
0.29
0.38
*
*
*
1.37
2.05
3.08
4.10
3.22
4.83
6.45
8.06
14.9
24.9
33.2
41.5
3.81
5.71
9.52
14.9
24.9
41.5
1.40
2.11
2.81
3.30
4.94
10.00
18.00
25.00

0.3
0.55
1.05
7
17
27
73
1.3
2.0
3.0
4.0
2.2
3.3
4.4
5.5
8.4
14.1
18.7
23.4
2.5
4.3
7.8
6.3
12.0
21.3
1.0
1.7
2.3
3.2
5.1
13.0
19.0
25.0
0.2
0.45
0.92
2.25
5.62
8.99
24.73
44.96
Table 9 Belt Tensioning Force
NOTE: Y = constant used in Equations (10-4) and (10-5).
* Not available at press time.
Belt 4 mm 6 mm 9 mm 12 mm 15 mm 20 mm 25 mm
2 mm GT2
3 mm GT2
5 mm GT2
3 mm HTD
5 mm HTD
T2.5
T5
T10
MXL
XL
2




0.34


2
2
3
8

5

0.67
3

3
3
4
11
18
9
13
1.37
7

3
4
5
15
22
12
18

4
5

19
27
16
24

12
28
5
6

25
35
22
33

43

43

41

9
Table 10 Static Belt Tension, T
st
(lbf) Per Span General Values
Belt 1/8" 3/16" 1/4" 5/16" 3/8" 7/16" 1/2"
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Most synchronous belt applications often exhibit their own individual operating characteristics. The static
installation tensions recommended in this section should serve as a general guideline in determining the level
of tension required. The drive system should be thoroughly tested to conrm that it performs as intended.
10.2 Making Measurements
Belt installation tension is generally measured in the following ways:
Force/Defection: Belt span tension can be measured by deecting a belt span 1/64" per inch (0.4 mm per
25 mm) of span length at midspan, with a known force (see Figure 20). This method is generally convenient,
but not always very accurate, due to difculty in measuring small deections and forces common in small
synchronous drives. The force/deection method is most effective on larger drives with long span lengths. The
static (or installation) tension (T
st
) can either be calculated from Equation (10-1) or Equation (10-2), or selected
from Table 9 or Table 10. The deection forces can be calculated from Equation (10-4) and Equation (10-5).
The span length can either be calculated from Equation (10-3), or measured. If the calculated static tension is
less than the minimum T
st
values in Table 9, use the minimum values.




PD pd


2
t = CD
2

(

)
(10-3)
2
where: t = Span length (in.)
CD = Drive center distance (in.)
PD = Large pitch diameter (in.)
pd = Small pitch diameter (in.)

t
T
st
+ () Y
L
Deection force, Min. = (lbf) (10-4)
16

t
1.1 T
st
+ () Y
L
Deection force, Max. = (lbf) (10-5)
16
where: T
st
= Static tension (lbf)
t = Span length (in.)
L = Belt pitch length (in.)
Y = Constant, from Table 9
Shaft Separation: Belt installation
tension can be applied directly by
exerting a force against either the driver
or driven shaft in a simple 2-point drive
system (see Figure 21). The resulting belt
tension will be as accurate as the force
applied to driver or driven shaft. This
method is considerably easier to perform
than the force/deection method and, in
some cases, more accurate.
In order to calculate the required shaft separation force, the proper static tension (on a per span basis)
should rst be determined as previously discussed. This tension value will be present in both belt spans as
tension is applied. The angle of the spans with respect to the movable shaft should then be determined. The
belt spans should be considered to be vectors (force with direction), and be summed into a single tension
vector force (see Figure 22). Refer to SECTION 14 BELT PULL AND BEARING LOADS for further instructions
on summing vectors.
Fig. 20 Force/Defection Method
Fig. 21 Shaft Separation Method
Fig. 22 Single Tension Vector Force
S
pan Length, t
Force
Deflection 1/64"
per inch of span
Separation
Force
Adjustment
Parallel
Motor
Parallel
Parallel
to Lower
Span
Parallel
to Upper
Span
Resultant
Tensioning
Force
Static Tension
Static Tension
Static Tension
Static Tension
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Idler Force: Belt installation tension can also be applied by exerting a force against an idler pulley within
the system that is used to take up belt slack (see Figure 23). This force can be applied manually, or with a
spring. Either way, the idler should be locked down after the appropriate tension has been applied.
Calculating the required force will involve a vector analysis as described previously in the shaft
separation section.
Soni c Tensi on Met er: The
Sonic Tension Meter (Figure 24) is an
electronic device that measures the
natural frequency of a free stationary
belt span and instantly computes the
static belt tension based upon the belt
span length, belt width, and belt type. This
provides accurate and repeatable tension
measurements while using a nonintrusive
procedure (the measurement process
itself doesn't change the belt span
tension). A measurement is made simply
by plucking the belt while holding the
sensor close to the vibrating belt span.
The unit is about the size of a portable phone (8-1/8" long x 3-3/4" wide x 1-3/8" thick or 206mm long x
95mm wide x 35mm thick) so it can be easily handled. The sensor is about 1/2" (13mm) in diameter for use
in cramped spaces, and the unit is either battery operated for portability or AC operated for production
use. The unit measures virtually all types of light power and precision belts. An automatic gain adjustment
allows measurements to be made in environments with high noise levels. A fully powered meter is necessary
for optimal microphone sensitivity. The meter has 3 settings standard (10 to 600 Hz), high (500 to 5000 Hz),
and low (10 to 50 Hz), but is normally set to standard. It is best to know the target belt span frequency, but
the appropriate range can be selected through trial and error. Data can also be collected through an IBM
Compatible RS-232 serial port, if desired. For additional details, see the product manual or page in the catalog.
SECTION 11 DRIVE ALIGNMENT
11.1 Angular And Parallel
Drive misalignment is one of the most common sources of drive performance problems. Misaligned drives
can exhibit symptoms such as high belt tracking forces, uneven belt tooth wear, high noise levels, and tensile
cord failure. The two primary types of drive misalignment are angular and parallel. Discussion about each of
these types are as follows:
Angular: Angular misalignment
results when the drive shafts are not
parallel (see Figure 25). As a result, the
belt tensile cords are not loaded evenly,
resulting in uneven tooth/land pressure
and wear. The edge cords on the high
tension side are often overloaded which
may cause an edge cord failure that
propagates across the entire belt width.
Angular misalignment often results in
high belt-tracking forces as well which
cause accelerated belt edge wear,
Fig. 23 ldler Forces
Backside Idler
Inside
Idler
Force
Force
Fig. 25 Angular Misalignment
Fig. 24 Sonic Tension Meter